Body Adhering Absorbent Article

ABSTRACT

The present invention provides a body adhering absorbent articles which is capable of absorbing bodily fluids. In particular embodiment of the present invention, provided is an absorbent article which is specifically designed for attachment to a wearer&#39;s skin in the vulva region of the wearer&#39;s torso.

This application is a divisional application of application Ser. No.11/890,093 entitled Body Adhering Absorbent Article and filed in theU.S. Patent and Trademark Office on Aug. 3, 2007. The entirety ofapplication Ser. No. 11/890,093 is incorporated herein by reference,

FIELD OF THE INVENTION

The present invention relates generally to an absorbent article forabsorbing bodily fluids.

BACKGROUND OF THE INVENTION

Absorbent personal care articles intended to absorb discharged bodyfluids are well known in the art. Such absorbent articles generallycomprise a fibrous mass or other absorbent core which can absorb andhold body fluids. Similarly, it is well known that feminine carearticles have been employed to absorb and hold liquids, such as urineand/or menses. A typical structure of an absorbent article includes afluid impermeable back sheet, a fluid permeable top sheet and anabsorbent core positioned between the back sheet and the top sheet.Prior absorbent articles have also included various other features toimprove fluid handling, such as intake layers, distribution layers,retention layers and the like. In these absorbent personal carearticles, the top sheet is the body-facing side of the absorbent articleand the back sheet is the garment-facing side of the absorbent article.

Generally, the absorbent articles are held into place during use byusing the wearer's waist and elastic materials in the waist portion ofthe absorbent product in place during use, in the case of pant-likegarments, such as diapers and training pants, or by attaching theabsorbent to the underwear or undergarment of a user, in the case ofpads or liners. Current methods of attaching the absorbent article tothe underwear or undergarment of a user include placing an adhesive onthe garment-facing side of the back sheet, having flaps (wings) extendfrom the longitudinal sides of the absorbent article which wrap aroundthe crotch portion of the underwear or undergarment of the user and acombination of the adhesive and the flaps.

It has also been suggested to use an adhesive to adhere the absorbentarticle to the skin of the user. However, the design of these absorbentarticles was essentially the same as the absorbent articles which wereattached to the underwear or undergarment of the user. That is, theadhesive is applied to the body-facing surface of the top sheet.Alternatively, in another design, a portion of the back sheet waswrapped around and over the top sheet. This portion of the back sheetwhich is wrapped around and over the top sheet becomes a body facingsurface. An adhesive is applied to the portion of the back sheet whichis wrapped over the top sheet. While these designs were effective foradhering the absorbent article to the skin of a user, these absorbentarticles were not comfortable for users to wear, since the shape andsize of the absorbent articles were the same as those absorbent articleswhich were attached to the undergarment or underwear of the user.

Similarly, absorbent articles that are attached to the underwear orundergarment of a user can also be uncomfortable for the user. This isbecause during normal movement of the body, portions of the body placeopposed forces on the undergarment, which may cause the undergarment tobe bunched or twisted. When this occurs, any absorbent article attachedto the underwear or undergarment may also become bunched or twisted,causing discomfort to the wearer of the absorbent article. For example,the presence and absence of pressure from the absorbent article on theinner thighs as the user moves, which is often described by users asfeeling “like a diaper”, is one source which compromises comfort forusers of conventional absorbent articles, including ultra-thin absorbentpads. In addition, the movement of the user may also cause the absorbentarticle to have a poor fit against the body of the user, which couldresult in leaks from the absorbent article.

Another disadvantage of conventional absorbent articles is that thesilhouette or outline of the absorbent article may be visible to othersthrough the clothing of the user. Even currently available ultra-thinabsorbent articles may be visible through tight fitting outer clothingof a user. Therefore, conventional absorbent personal care articles donot always provide discretion for users.

There is a need in the art to provide users of absorbent articles with adiscrete absorbent product, which is comfortable to wear and willeffectively prevent or reduce premature leakage from the absorbentarticle.

SUMMARY OF THE INVENTION

Generally stated, the present invention provides a body-adheringabsorbent article which is capable of absorbing bodily fluids.

In one embodiment of the present invention, an absorbent article forattachment to a wearer's skin in the vulva region of the wearer's torsois provided. The absorbent article has a shell having a first side and asecond side, the first side having a first area and a second area. Thefirst area surrounds the majority of the second area. Located within thesecond area is an absorbent structure containing an absorbent material.In this embodiment, the first area of the shell is designed to attachand/or adhere to the wearer's skin surrounding the vulva region of thefemale torso, when the absorbent article is applied to the wearer. Theshell is sized and shaped such that the extent of the first area of theshell only contacts the skin proximate to the vulva of the wearer, andmay attach to the pubic and/or the perineal regions of the body of theuser.

In another embodiment of the present invention, provided is an absorbentarticle for attachment to a wearer's skin in the vulva region of thewearer's torso. This absorbent article has a three-dimensional concaveshape that the first side of the shell is an inward curving surface.Attached to the shell or integrated with the shell is an absorbentstructure.

The absorbent articles of the present invention may be used as apantiliner, a sanitary napkin or an incontinence absorbent product. Inaddition, the absorbent article may be worn as an underwear substitutesince the absorbent article does not need underwear hold the absorbentarticle in place. As an underwear substitute, the absorbent articleprovides protection to the vulva area by creating a barrier between theclothing and the vulva.

By providing the disposal absorbent article of the present invention,drawbacks of the conventional absorbent personal care articles areminimized.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B each show a top view of an embodiment of an absorbentarticle of the present invention.

FIGS. 2 and 2A each show a side cross-sectional view of an embodiment ofan absorbent article of the present invention.

FIG. 3 shows a side view of another embodiment of an absorbent articleof the present invention wherein the shell has a concave shape.

FIG. 4 shows a cross-sectional side view of an absorbent article of thepresent invention with the absorbent core recessed into the shell.

FIGS. 5, 5A and 5B each show a top view of an embodiment of an absorbentarticle of the present invention having a different shell shape.

FIG. 6A shows a bottom view of an embodiment of an absorbent article ofthe present invention where only a portion of the absorbent structure ispositioned over shell.

FIG. 6B shows a top view of an embodiment of an absorbent article of thepresent invention where only a portion of the absorbent structure ispositioned over shell.

FIG. 6C shows a cross-sectional view taken along sectional line 6C-6C.

FIG. 7 shows a top view of an embodiment of an absorbent article of thepresent invention wherein the body adhesive is applied in an openpattern.

FIGS. 8A, 8B and 8C each show an absorbent article of the presentinvention having a release sheet applied thereto.

FIG. 9 shows a top view of another absorbent article of the presentinvention having a design for attachment to specific area of the body

FIG. 10 shows a cross-section view of FIG. 9 along lines 9-9.

FIG. 11A and FIG. 11B shown embodiments of the present invention withplacement guides.

DEFINITIONS

It should be noted that, when employed in the present disclosure, theterms “comprises”, “comprising” and other derivatives from the root term“comprise” are intended to be open-ended terms that specify the presenceof any stated features, elements, integers, steps, or components, andare not intended to preclude the presence or addition of one or moreother features, elements, integers, steps, components, or groupsthereof.

It should be understood that the term “absorbent product” or “absorbentarticle”, as used herein, refers to any article used to control bodilyfluids that are configured to absorb and retain bodily exudates,including urine, blood, menses, and other bodily discharges, such assweat and vaginal secretions resulting from sexual activity and thelike.

As used herein, the term “polymer” generally includes, but is notlimited to, homopolymers, copolymers, such as for example, block, graft,random and alternating copolymers, terpolymers, etc., and blends andmodifications thereof. Furthermore, unless otherwise specificallylimited, the term “polymer” shall include all possible geometricalconfigurations of the material. These configurations include, but arenot limited to, isotactic, syndiotactic and random symmetries.

As used herein, “body-facing surface” means that surface of theabsorbent article which is intended to be disposed toward or placedadjacent to the body of the wearer during ordinary use. The“garment-facing surface” is on the opposite side of the absorbentarticle from the body-facing surface. The garment-facing surface is anoutward surface of the absorbent article and is intended to be disposedto face away from the wearer's body during ordinary use. Thegarment-facing surface is generally arranged to face toward or placedadjacent to the wearer's undergarments when the absorbent article isworn.

As used herein, the term “connected” is intended to mean directlyconnected and indirectly connected. By directly connected, it isintended that the connected elements are in contact with one another oraffixed to one another. By indirectly connected, it is intended that oneor more intervening or intermediate elements are between the twoelements which are secured or “connected” together. The interveningelements may be affixed.

As used herein, the term “absorbent structure” is intended to mean aconfiguration of an absorbent material which allows fluids to beabsorbed by the absorbent material.

DETAILED DESCRIPTION OF THE INVENTION

The absorbent product of the present invention provides an absorbentarticle which is designed to adhere to the body of a user in the area ofthe body of the user which may need bodily fluids absorbed. In oneparticular use of the absorbent article, the absorbent article isattached to the body of a female user to or around the vulva region ofthe body. By “to or around the vulva region”, it is meant adjacentregions of the body of a female including the pubic region and theperinea region. When applied to or around the vulva region of the femalebody, the absorbent article may be used as a pantiliner, sanitary napkinor incontinence article. In addition, the absorbent article may be wornas an underwear substitute since the absorbent article of the presentinvention does not need underwear hold the absorbent article in place.As an underwear substitute, the absorbent article provides protection tothe vulva area by creating a barrier between the outer clothing and thevulva of a user. When worn as an underwear substitute, the absorbentarticle serves to protect the outer clothing of the wearer from bodilydischarges from the vulva region of the user's body. In addition, whenthe absorbent article is worn as an underwear substitute, the absorbentarticle also serves to protect the sensitive skin and body features ofthe vulva region from roughness of the outer clothing, there bypreventing or alleviating irritation to the sensitive skin and bodyfeatures of the vulva region.

To gain a better understanding of the present invention, attention isdirected to the Figures of the present specification. As is shown ineach of the Figures, the absorbent article 10 has a longitudinaldirection 1 and a lateral direction 2. One component of the absorbentarticle is a shell 14. This shell 14 has a first side 15 and a secondside 17, as is shown in FIGS. 2 and 4. The shell 14 serves to providethe overall contour or silhouette of the absorbent article of thepresent invention. In addition, the shell 14 also provides a surface forattachment or adhesion of the absorbent article 10 to the body of auser.

The first side 15 of the shell 14 is the body facing side of theabsorbent article 10 and the second side 17 of the shell 14 is thegarment facing side of the absorbent article. The first side 15 of theshell 14 has a first area 11 and a second area 12. The first area 11surrounds or bounds the majority of the second area 12, as is clearlyshown in FIG. 1A. By “surrounds or bounds the majority”, it is meantthat at least 51% of the circumference 12C of the second area 12contacts the first area 11. Generally, at least 60% of the circumference12C of the second area 12 contacts the first area 11. In a particularembodiment, at least 75% of the circumference 12C of the second area 12is in contact with the first area 11. In another particular embodiment,at least 90% of the circumference 12C of the second area 12 is incontact with the first area 11. In a further embodiment of the presentinvention, at least 95% of the circumference 12C of the second area 12is in contact with the first area 11. In a further embodiment of thepresent invention, the first area 11 completely surrounds the secondarea 12 of the shell 14 as is shown in FIG. 1B.

In one embodiment, the first area 11 of the first side of the shell 14is designed or adapted to contact, attach or adhere to the wearer'sskin. In one particular embodiment, the first area 11 of the shell 14 isdesigned or adapted to contact a female wearer's skin surrounding thevulva region of the female torso when the absorbent article 10 isapplied to the wearer. By “designed or adapted to contact a femalewearer's skin surrounding the vulva region of the female torso”, it ismeant that the size and shape of the shell is such that the shell fitsin the vulva region and possibly the surrounding pubic region andperinea regions of the female torso.

Generally, the shell 14 is sized and shaped such that the extent of thefirst area of the shell only contacts and attaches or adheres to theskin surrounding and proximate to the vulva area and possibly the pubicand perinea regions of the wearer. In addition to contacting the skin inthe vulva, pubic and perinea regions of the wearer, the first area 11 ofthe first area of the shell 14 may also contact and attach or adhere toany hair in the vulva area of the user which may be present. The firstarea 11 is the portion of the first side 15 of the shell 14 which holdsthe absorbent article in place on the user.

Generally, the second area 12 of the shell 14 is the portion of theshell 14 which provides absorbency to the absorbent product. That is,the second area 12 of the first side to the shell is any area of thefirst side of the shell which has an absorbent structure attachedthereto, or has absorbent properties. In one particular embodiment ofthe present invention, the second area 12 of the shell 14 has anabsorbent structure 21 contained therein or attached to the shell 14 inthe second area. It is noted that the second area 12 may be a singlecontiguous area or may be two or more distinct areas. Generally, thesecond area 12 is a single contiguous area from an ease of manufacturingstandpoint. In an alternative embodiment, the second area 12 of theshell may contain an absorbent material integrated into the shell 14,such that the second area 12 of the shell is absorbent without thepresence of an additional absorbent structure. The second area 12 shellmay have an absorbent material coated or impregnated into the shellmaterial.

To gain a better understanding of the vulva region and surround regionsof the female body, a general description of the anatomical structurescan be found in The Illustrated Running Press Edition of the AmericanClassic Gray's Anatomy (1974) by Henry Gray and Structure and Functionin Man (1974) by Stanley W. Jacob, M.D., F.A.C.S. and relevant portionsare included herein by reference. The general form can be found inAnatomy for an Artist: Elements of Form by Eliot Goldfinger and relevantportions are included herein by reference. The general description ofthe pubic hair covering these regions can be found in Woman's Body: AManual for Life and relevant portions are included herein by reference.

The female anatomical structures to be described include the leg and thelower torso. The external anatomical structures of the lower torsoinclude gluteal region and perineum region. The gluteal region includesthe buttocks and the anus. The anatomical structure involved on the legis the medial surface of the upper thigh.

The gluteal region includes generally the buttocks and anus and istypically bound in front by the line of the buttocks and the glutealfolds, in the back by the sacral triangle and the sides by linesextending through the greater trochanters. The shape of the glutealregion is roughly hemi-spherical and convex, and is determined by aseries of muscles including the gluteus maximus and a series of fat padsincluding the posterior gluteal fat pad. The line of the buttocksseparates the gluteal region and the perineum region.

The upper thigh region includes typically the right and left thigh andis typically bound on top by the thigh lines and the sides by the frontand back of the leg. The thigh lines are two lines that are on eitherside of the labia and each of the lines runs along the line of theinguinal ligment to the gluteal folds and marks where the upper thighmeets the lower torso. The shape of the region is roughly a portion of atapered cylinder and convex, and is shaped by a series of muscle groupsincluding the gracilis, pectineus, adductor longus, adductor brevis, andadductor magnus and series of fat pads including the inner thigh fatpad.

The perineum region, which extends from the inferior outlet of thepelvis to the bony structure of the coccyx, is comprised of twodivisions, the urogenital triangle and the anal division or obstetricalperineum. The region includes the external organs of reproduction; themons pubis, labia majora and minora, clitoris, meatus urinarius and theopening to the vagina. The region is generally bound in front by thelower abdominal line, on the sides the thigh lines, and in the back theline of the buttocks. The abdominal line is a line that passes acrossthe top of the pubis. The lines of the buttocks are lines that connectthe thigh lines to the gluteal cleft. For convenience in describing theform and created spaces in the perineum region, this region will besubdivided into three regions including an anterior region including themons pubis, a central region including the labia majora and minora, andposterior region. The anterior region is bound in front by the lowerabdominal line, in back by anterior commissure, and on the sides by lineof the labia. The central region is bound in front by the anteriorcommissure, in the back by the posterior commissure, and on the side bythe line of the labia. The posterior region is bound in front by theline of the labia, in the back by the lines of the buttocks, and on thesides the thigh line.

The vulva region includes the female external genitalia and generallyincludes the anterior and central regions of the perineum. The monspubis [or veneris] is generally a rounded eminence in front of thesymphysis pubis, formed by a collection of fatty tissue including thepubic fat pad beneath the integument and is generally covered with pubichair. The labia majora are generally two prominent longitudinalcutaneous folds extending downward from the mons veneris to the anteriorboundary of the perineum, and generally enclosing the commonurinary-sexual opening. The space between the two folds is the labialcleft. Each labium has generally two surfaces, an outer, which ispigmented and covered generally with strong, crisp pubic hairs, and aninner within the labia cleft, which is smooth and is beset with largesebaceous follicles and is continuous with the genito-urinary mucoustract; between the two there is considerable quantity of areolar tissue,fat including the labia fat pad, and tissue besides vessels, meeting theanterior commissure. Posteriorly they are typically not joined, butgenerally appear to become lost in the neighboring integument,terminating close to, and nearly parallel with each other. Together withthe connecting skin between them, they form the posterior commissure orposterior boundary of the vulval orifice. The interval between theposterior commissure and the anus constitutes the perineum region. Thefourchette is the anterior edge of the perineum, and between it and thehymen is a depression, the fossa navicularis. The line of the labiaseparates the labia and the perineum region.

The labia minora are two small cutaneous folds, situated generallywithin the labia majora, and extending from the clitoris obliquelydownward, outward, and backward on each side of the orifice of thevagina, between which and the labia majora they are lost.

The form of the perineum, gluteal, and upper thigh regions combine toform a very intricate skin topography and spaces. The roughlytwo-hemispherical-like forms of the buttocks, the roughlytapered-cylinder-like form of the upper thigh, split-teardrop-like formof the vulvar region create intricate generally convex topography withintersections to form a series of recesses. The generally convextopography of the buttocks, the vulvar region, and upper thigh join tocreate spaces including two inner thigh grooves along two thigh lines, adepression in the posterior perineum region and a cleft extendingthrough the labia and gluteal clefts. The grooves, depression, and cleftare like interconnected recesses in the topography. The central regiongeneral has lateral sides separated by a distal surface created by thelabial cleft and includes the labial cleft.

Pubic hair generally cover some of these regions and fill in a portionof these recesses especially the labial cleft and the portion of thegroove of the thigh parallel to the labial cleft to create a hairsurface topography. The hair topography is the surface topography of animaginary distal surface created by the hair. The depression of theperineum, thigh groove parallel to the gluteal cleft, and the glutealcleft generally has little or no pubic hair. The skin topographycombines with the hair topography to create an overall body topography.

This intricate space created by the intricate body form in this regionof the body varies between women in both size and form, and varies withthe position and movement of the women. Some of these variations aresummarized in “Female genital appearance: ‘normality’ unfolds” byJillian Lloyd et. al., BJOG: An International Journal of Obstetrics andGynecology, May 2005, Vol. 112, pp. 643-646 and is included herein byreference.

The shell 14 of the absorbent article 10 may be prepared from a varietyof materials. The shell may include a layer constructed of any materialwhich will function to be operatively liquid impermeable. The shell 14may, for example, include a polymeric film, a woven fabric, a nonwovenfabric or the like, as well as combinations or composites thereof. Forexample, the shell 14 may include a polymer film laminated to a woven ornonwoven fabric. A laminate shell 14 structure is shown in FIG. 2A,having an upper layer 141 and a lower layer 142, wherein the upper layeris the body-facing side of the shell 14 and the lower layer 142 is thegarment facing side of the shell 14. In a particular feature, thepolymer film can be composed of polyethylene, polypropylene, polyester,silicone or the like, as well as combinations thereof. Additionally, thepolymer film may be micro-embossed, have a printed design, have aprinted message to the consumer, and/or may be at least partiallycolored. Suitably, the shell 14 can operatively permit a sufficientpassage of air and moisture vapor out of the absorbent article 10,particularly out of an absorbent structure 21 while blocking the passageof bodily fluids and odors often associated with bodily fluids. Anexample of a suitable shell material can include a breathable,microporous film, such as those described in, for example, U.S. Pat. No.6,045,900 to Haffner et al., the entire disclosure of which isincorporated herein by reference and made a part hereof. Other shellmaterials which are extensible may be used in the present invention.Examples of extensible backsheet materials are described in U.S. Pat.No. 5,611,790, issued Mar. 18, 1997, to Osborn, III et al., hereinincorporated by reference in its entirety.

In one particular embodiment of the present invention, the shell 14 maybe a laminate of a woven or nonwoven fabric with a silicone polymer,wherein the silicone polymer has adhesive properties. The second side 17of the shell will be woven or nonwoven fabric and the first side 15 ofthe shell will be silicone polymer. One commercially available laminateis an Oleeva Fabric® I available from Bio Med Sciences, Inc., which haveoffices at 7584 Morris Court, Suite 218 Allentown, Pa. 18106. The OleevaFabric® is a silicone sheeting having adhesive properties laminated to afabric backing. The silicone sheeting will form the body facing firstside 15 of the shell material. Relating this particular structure to theFigures, in FIG. 2A, the silicone polymer is the upper layer 141 of theshell 14 and the nonwoven or woven layer is the lower layer 142 of theshell.

Bicomponent films or other multi-component films can also be used as theshell 14 material. In addition, woven and/or nonwoven fabrics which havebeen treated to render them operatively liquid-impermeable can also beused as an effective shell 14 material. Another suitable shell materialcan include a closed-cell polyolefin foam, a polyurethane polymermaterial, a silicone polymer or other similar materials. Siliconepolymers having naturally occurring adhesive properties, or siliconepolymers having a silicone adhesive layer applied thereto are ofparticular interest for the shell material. Such silicone polymers willallow the first area 11 of the shell 14 to adhere to the body of theuser without the need of an additional adhesive. These materials may belaminated to another material such that the second side 17 of the shell14, which is the garment facing side of the absorbent article 10, sothat the adhesive nature of the silicone polymer does not adhere thegarment of under garments of the user. In another embodiment of thepresent invention, the shell material may be prepared from aninterpenetrating polymer network or two or more polymers. Generally, oneof the polymer of the interpenetrating polymer network may be a siliconematerial. Examples of interpenetrating polymer networks are described inU.S. Pat. No. 5,759,560, issued to Dillion, which is hereby incorporatedby reference in its entirety.

The shell material should be selected such that the overall propertiesof the shell allow the shell material to move the skin of the userduring normal use and normal movements by the user during use. By“normal movement by the user” it is meant any movement that normallyoccurs during use of the absorbent article, including, walking, running,sitting, standing, kneeling, riding a bicycle, exercising, playingsports, getting into and out of an automobile, and other similarmovements made by users when wearing an absorbent article. The shellshould not be too rigid, such that the shell detaches from the skin ofthe user during use and the shell should not be so flexible that theshell tends to twist and bunch during use. The shell should havesufficient flexibility to conform to the skin of the user and becomesimilar to a second skin of the user.

Generally, the shell material should have sufficient thickness to allowthe shell 14 to mold to the body of the user, but not too thick that theshell 14 becomes uncomfortable for the user to wear. In addition, theshell 14 should not be so thin that it ineffectively forms a seal withthe skin of the user when applied to the user, or becomes detached fromthe skin of the user during use and normal movement of the user duringuse or that it does not adequately conform to the shape and skin of theuser at the point of attachment to the user. Depending on the materialused for the shell, the typical thickness of the shell is between 0.03mm and about 5.0 mm, more particularly between 0.1 mm and 3.0 mm. In oneparticular embodiment, the thickness of the shell is between 0.25 mm andabout 3.0 mm. Again, the actual thickness used is dependent of severalfactors including rigidity of the material, the flexibility of thematerial and the ability of the material to assume the shape of the skinof the user at the location of use, which is typically the vulva regionof a user.

The second side 17 of the shell 14 forms the garment-facing side of theabsorbent article when worn by a user. The shell material should beselected such that the second side of the shell will freely move againstthe undergarment or clothing of a user. One way to achieve this resultis to have the second side 17 of the shell 14 to have a fairly lowcoefficient of friction. This will allow the second side 17 of the shell14 to freely move against the undergarment or other clothing worn by theuser. If the second side 17 of the shell 14 does not freely move againstthe undergarment or other clothing worn by the user, the absorbentarticle may catch on the undergarment or clothing, which may result inthe absorbent article being prematurely and undesirably removed from theuser or may cause the absorbent article to be shifted from its desiredplacement against the body of a user.

In order to achieve the desired coefficient of friction on the secondside 17 of the shell 14, the materials used to prepare the shell couldbe selected such that the second side 17 of the shell material willinherently have the desired coefficient of friction. Alternatively, thesecond side 17 of the shell 14 may be treated with a coatingcomposition, such a polytetrafluoroethylene containing coating, asilicone containing coating or other similar coating having lowcoefficient of friction properties. Alternatively, the shell 14 could bemade from a laminate of two or more materials such that the first side15 of the shell 14 is prepared from a material which meets the neededproperties of the first side 15, while the material selected for thesecond side 17 of the shell 14 meets the desired coefficient of frictionsuch that the second side 17 will free move against the undergarment orgarment being worn by a user.

The shell 14 of the absorbent article 10 may be flat or may have athree-dimensional shape. As is shown in FIG. 3, which is a sideperspective view of the absorbent article the shell 14 has athree-dimensional concave shape. Alternatively, as is shown incross-sectional side views of FIGS. 2, 2A and 4, the shell 14 may have agenerally flat shape. By providing the absorbent article 10 with athree-dimensional concave shape as is shown in FIG. 3, placement of thearticle may be easier for the user. Generally, the three-dimensionalshape could be such that it closely matches the overall generalcurvature of the vulva region and optionally the pubic and perinearegions of most women, when the absorbent article is used as apantiliner, sanitary napkin or a feminine incontinence article. To formthe shell 14 with a three-dimensional shape, the shell may be molded inany manner known to those skilled in the art, for example heat molding.The manner in which the three-dimensional shape is imparted to the shell14 is not critical to the present invention.

When the shell 14 is a flat shape, meaning that the shell does not havea third dimension other than thickness, the shell 14 should be made tobe flexible enough that the shell 14 can conform to the body of the userat the point of attachment. In addition to being flat, the overall shapeof the shell 14 may be contoured, as is shown in FIGS. 5, 5A and 5B. Inone embodiment, the contour shape may be such that the narrowest pointof the contour is in the crotch area of the shell 14 nearest the vulvaregion, as is shown in FIG. 5A. The contour shape shown in FIG. 5 is oneof many possible shapes the shell 14 and absorbent article may beprepared. Other shapes may be used, without departing from the scope ofthe present invention. Generally, the shape selected should be such thatthe shell 14 and absorbent article 10 are comfortable for the user towear, while providing leakage protection to the user. It is noted that acontour shape may also be used in conjunction with a three-dimensionalshell. Further discussion of the overall shape of the absorbent articlemay be found below.

The shell may be any desired color or may be translucent. In addition,the shell may have a matt finish, satin finish or a smooth finish. Theparticular finish color or translucency can be a matter of choice forthe manufacturer of the absorbent article of the present invention.However, by providing a shell which is translucent may assist the userin placing the absorbent article 10 prior to use, since the user may beable to see where the article is placed compared to the genitalia of theuser.

The absorbent structure 21 is designed to absorb body exudates,including menstrual fluid, blood, urine, and other bodily fluids, suchas sweat and vaginal discharges. The absorbent structure 21 has alongitudinal direction 1 and a lateral direction 2. This absorbentstructure 21 may be a single layer or may be multiple layers. Typically,the absorbent structure 21 has an absorbent core 22. This absorbent core22 may contain one or more layers of absorbent materials. That is theabsorbent core 22 may be a single layer of absorbent materials or may bea multilayer structure. Each of the layers can contain similar materialsor different materials. In the absorbent article 10 of the presentinvention, the materials which may be used to form the absorbent core 22include those materials conventionally used in absorbent articles andincludes materials, such as, for example, cellulose, wood pulp fluff,rayon, cotton, and meltblown polymers such as polyester, polypropyleneor coform. Coform is a meltblown air-formed combination of meltblownpolymers, such as polypropylene, and absorbent staple fibers, such ascellulose. A desired material is wood pulp fluff, for it is low in cost,relatively easy to form, and has good absorbency.

The absorbent core 22 can also be formed from a composite comprised of ahydrophilic material which may be formed from various natural orsynthetic fibers, wood pulp fibers, regenerated cellulose or cottonfibers, or a blend of pulp and other fibers. One particular example of amaterial which may be used as the absorbent core is an airlaid material.The absorbent core 22 may have other properties including extensibility,which will allow the absorbent core to be extended or fit to aparticular user. One example of extensible absorbent cores is describedin U.S. Pat. No. 5,611,790, issued Mar. 18, 1997, to Osborn, III et al.,herein incorporated by reference in its entirety.

In one embodiment, the absorbent core 22 may also include asuperabsorbent material, in addition to or in place of the hydrophilicmaterial, which increases the ability of the absorbent core to absorb alarge amount of fluid in relation to its own weight. Generally stated,the superabsorbent material can be a water-swellable, generallywater-insoluble, hydrogel-forming polymeric absorbent material, which iscapable of absorbing at least about 15, suitably about 30, and possiblyabout 60 times or more its weight in physiological saline (e.g. salinewith 0.9 wt % NaCl). The superabsorbent materials can be inserted asparticles or in sheet form. The superabsorbent material may bebiodegradable or bipolar. The hydrogel-forming polymeric absorbentmaterial may be formed from organic hydrogel-forming polymeric material,which may include natural material such as agar, pectin, and guar gum;modified natural materials such as carboxymethyl cellulose, carboxyethylcellulose, and hydroxypropyl cellulose; and synthetic hydrogel-formingpolymers. Synthetic hydrogel-forming polymers include, for example,alkali metal salts of polyacrylic acid, polyacrylamides, polyvinylalcohol, ethylene maleic anhydride copolymers, polyvinyl ethers,polyvinyl morpholinone, polymers and copolymers of vinyl sulfonic acid,polyacrylates, polyacrylamides, polyvinyl pyridine, and the like. Othersuitable hydrogel-forming polymers include hydrolyzed acrylonitrilegrafted starch, acrylic acid grafted starch, and isobutylene maleicanhydride copolymers and mixtures thereof. The hydrogel-forming polymersmay be lightly crosslinked to render the material substantially waterinsoluble. Crosslinking may, for example, be by irradiation or covalent,ionic, Van der Weals, or hydrogen bonding. Hydroxyfunctional polymershave been found to be good superabsorbents for sanitary napkins. Suchsuperabsorbents are commercially available from Dow Chemical,Hoechst-Celanese, and Stockhausen, Incorporated, among others, and are apartially neutralized salt of cross-linked copolymer of polyacrylic acidand polyvinyl alcohol having an absorbency under load value above 25grams of absorbed liquid per gram of absorbent material (g/g). Othertypes of superabsorbent materials known to those skilled in the art canalso be used.

Generally, the absorbent core 22 will be positioned adjacent the shell14, as is shown in FIGS. 2, 2A and 4. In addition, the absorbent core 22may be recessed into the shell 14 as is shown in FIG. 4. By “adjacent tothe shell”, it is meant that the that the absorbent core 21 is directlyin contact with the shell or may be separated by one or two additionallayers or a construction or pressure sensitive adhesive.

In addition to the absorbent core 22, the absorbent structure 21 mayhave other additional layers which aid the absorbent core 22 incapturing and holding the bodily fluid into the absorbent core 22. Theseother layers, when present, in combination with the absorbent core 22form the absorbent structure 21 of the absorbent article 10. There maybe a single layer or multiple layers in addition to the absorbent corein the absorbent structure 21. Alternatively, the absorbent structure 21may have a single layer, which is generally the absorbent core 22.

One particular example of an additional layer which may be used inaddition to the absorbent core 22 in the absorbent structure 21 is abody-side liner or top sheet 24, which is generally a liquid permeablematerial, which allows bodily fluids to pass through the top-sheet intothe absorbent core. It is noted that the terms “body-side liner” and“top sheet” may be used interchangeable. The body side liner 24 also mayprovide a user with a dry feeling by separating the absorbent core 22from the body of the user. That is, the body-side liner 24 is placedbetween the absorbent core 22 and the body of the user and such that theabsorbent core 22 is between the body side liner 24 and the shell 14.

In the present invention, generally the body side liner 24 will onlyextend to the edge 25 of the absorbent core, as is shown in FIG. 2.However, the body side liner 24 may extend beyond the edge 25 of theabsorbent core 22 and may be attached to the first side of the shell.Generally, if the body side liner 24 extends beyond the absorbent core22, the body side liner will be attached to the first side 15 of theshell 14. Also, if the body side liner 24 extends beyond the absorbentcore 22, the body side liner 24 will generally not cover the entirefirst area 11 of the first side 15 of the shell 14.

Optionally, the body side liner 24 may be formed from one or morematerials. The body-side liner or top sheet 24 should be able to managedifferent body excretions depending on the type of product. In femininecare products, often the body-side liner or top sheet 24 must be able tohandle menses and urine. In the present invention, the body-side lineror top sheet 24 may include a layer constructed of any operativematerial, and may be a composite material. For example, the body-sideliner or body-contacting layer can include a woven fabric, a nonwovenfabric, a polymer film, a film-nonwoven fabric laminate or the like, aswell as combinations thereof. Examples of a nonwoven fabric useable inthe body-side liner or top sheet 24 include, for example, an airlaidnonwoven web, a spunbond nonwoven web, a meltblown nonwoven web, abonded-carded web, a hydroentangled nonwoven web, a spunlace web or thelike, as well as combinations thereof. Other examples of suitablematerials for constructing the body-side liner or top sheet 24 caninclude rayon, bonded-carded webs of polyester, polypropylene,polyethylene, nylon, or other heat-bondable fibers, finely perforatedfilm webs, net-like materials, and the like, as well as combinationsthereof. These webs can be prepared from polymeric materials such as,for example, polyolefins, such as polypropylene and polyethylene andcopolymers thereof, polyesters in general including aliphatic esterssuch as polylactic acid, nylon or any other heat-bondable materials.When the body-side liner is a film or a film laminate, the film shouldbe apertured or otherwise be made to allow fluids to flow through thebody-side liner to the absorbent core.

Other examples of suitable materials for the body-side liner or topsheet 24 are composite materials of a polymer and a nonwoven fabricmaterial. The composite materials are typically in the form of integralsheets generally formed by the extrusion of a polymer onto a nonwovenweb, such as a spunbond material. In a particular arrangement, thebody-side liner or top sheet layer 24 can be configured to beoperatively liquid-permeable with regard to the liquids that the articleis intended to absorb or otherwise handle. The operativeliquid-permeability may, for example, be provided by a plurality ofpores, perforations, apertures or other openings, as well ascombinations thereof, which are present or formed in the liner or bodycontacting layer. The apertures or other openings can help increase therate at which bodily liquids can move through the thickness of the lineror body contacting layer and penetrate into the other components of thearticle (e.g. into the absorbent core 22). The selected arrangement ofliquid permeability is desirably present at least on an operativeportion of the body-side liner or top sheet 24 that is appointed forplacement on the body-side of the article. The body-side liner or topsheet 24 can provide comfort and conformability, and can function todirect bodily exudates away from the body and toward the absorbent core22. The body-side liner or top sheet 24 can be configured to retainlittle or no liquid in its structure, and can be configured to provide arelatively comfortable and non-irritating surface next to the bodytissues of a wearer. In the present invention, the top sheet orbody-facing surface of each absorbent article may be embossed, printedor otherwise imparted with a pattern.

Additional layers or substrates, including for example, the liquidacquisition and distribution layer, also referred to as a surge ortransfer layer, and an optional tissue layer are also incorporated intothe absorbent structure 21 of the absorbent product 10, for example,between the body-side liner or top sheet 24 and the absorbent core 22.The distribution layer may be shorter than the absorbent core or havethe same length as the absorbent core 22. The distribution layer servesto temporarily hold an insulting fluid to allow the absorbent coresufficient time to absorb the fluid, especially when a superabsorbentmaterial is present.

In another embodiment, the absorbent core, transfer layer and othercomponents, such as tissue layers, may be free floating (unattached)between the shell 14 and the top sheet 24, and only are secured alongonly the peripheral edges thereof. Alternatively, the absorbent core 22,transfer layer, if present, and any other layer or component, ifpresent, may be attached to one or both of the shell 14 and top sheet 24and/or to each other.

The absorbent structure 21, including the absorbent core, is generallyattached to the first side 15 of the shell 14 in the second area 12 ofthe shell. The attachment may be in a permanent manner, meaning that theabsorbent structure is generally intended not to be removable by theuser of the absorbent article 10. Alternatively, the absorbent structure21 may be made to be removable by the user, meaning that the absorbentstructure 21 may be removed and replaced with another absorbentstructure 21 by the user of the absorbent article 10. When the absorbentstructure 21 is attached to the shell 14 in a permanent manner, meaningthat the absorbent structure is not intended to be removed by the user,a construction adhesive may be used. Examples of useable constructionadhesives include any adhesive which will effectively hold the absorbentstructure 21 in place, so as not to be separated from the shell 14.Commercially available construction adhesives usable in the presentinvention include, for example include Rextac adhesives available fromHuntsman Polymers of Houston, Tex., as well as adhesives available fromBostik Findley, Inc, of Wauwatosa, Wis. Other means may be used to holdthe absorbent structure 21 to the shell including other bonding means,including heat bonding and ultrasonic bonding. When the absorbentstructure 21 is removably attached, the absorbent structure 21 is heldin place on the shell 14 by a means which will allow the user to removethe absorbent structure. One such means of holding the absorbentstructure is by using a pressure sensitive adhesive. Suitable pressuresensitive adhesives include any commercially available pressuresensitive adhesive. Examples of suitable pressure sensitive adhesivesusable to removably hold the absorbent structure 21 in place on theshell 14 include pressure sensitive adhesives available from NationalStarch and, having offices in, Bridgewater, N.J. 08807. By providing anabsorbent structure which is removable, the shell may be reused severaltimes without the need to again place the shell when the absorbent needsto be replaced. Also by having a removable absorbent structure, theabsorbent structure can be selected by the user prior to use. This wouldallow the user to select an appropriate level of protection for a givenday or allow the user to select a size or shape of the absorbent whichthe user finds to be more comfortable.

As is stated above, the absorbent structure 21 is located in the secondarea 12 of the shell 14 and on the first side 15 of the shell member.This size and shape of the absorbent structure may be varied dependingof the intended use of the absorbent article and will be discussed inmore detail below.

The absorbent structure 21 may a relatively flat structure, as shown inFIGS. 2, 2A, 3 and 4. Alternatively, the absorbent structure may have athree-dimensional shape other that a relatively flat shape. Theabsorbent structure may have an anatomically correct shape such that theabsorbent structure fits within the labia of the user. Anatomicallycorrect shapes of absorbent are generally know to those skilled in theart and are generally found in the interlabial art field. The absorbentstructure may be designed to be partially or fully interlabial.Alternatively, a three-dimensional shaped absorbent structure may alsobe used in the absorbent article 10 which is designed not to fit withinthe labia majora of the user. That is, the absorbent structure 21 ispositioned completely outside the labia during use The size, locationand shape of the absorbent structure 21 may also be selected for anintended use. For example, in an overnight use, the absorbent may belocated further back on the user towards the perinea region of the user.In an overnight use, the absorbent structure may be larger than in aproduct intended for daytime use. In a daytime use, the absorbentstructure will generally be centrally located of the vulva region.

In an alternative embodiment of the present invention, the absorbentstructure 21 is contained within the shell material. That is, theabsorbent structure 21 is an integral part of the shell 14 and aseparate absorbent structure is not present. One way to achieve anintegral absorbent structure is to have a shell which is prepared from amaterial which is a laminate of two or more materials. The first side 15of the shell 14 contains an absorbent material within the body facingside of the laminate. For example, superabsorbent particles or materialsmay be incorporated into the material making up the body facing layer ofthe laminate. Another way is to place a very light coating onto thefirst side 12 of the shell material, wherein the coating contains asuperabsorbent particles or materials. Of course other absorbentmaterials, other than superabsorbent materials may be used in place ofor in addition to the superabsorbent materials.

The absorbent structure 21 may be located entirely over the shell 14, asis shown in FIGS. 1, 2, 2A, 3, 4 and 5, meaning at the shell 14 materialis located beneath the absorbent structure 14. Alternatively, theabsorbent structure 21 may be positioned over the shell 14, such thatonly a portion of the absorbent structure 21 is over the shell 14. Thisconfiguration is shown in FIGS. 6A, 6B and 6C. FIG. 6A is a bottom viewand FIG. 6B is a top view of an absorbent article 10 within the presentinvention. As can be seen only a portion of the absorbent structure 21is positioned over the shell 14. FIG. 6C shows a cross-sectional view ofthe absorbent article 10 taken along line 6C-6-C in FIG. 6B. As with theother embodiments of the present invention, the portion of the firstside 15 of the shell 14 in which the absorbent structure is attached isthe second area 12 of the shell 14. Surrounding the second area 12 isthe first area 11 of the shell 14. The second side 17 of the shell 14 isthe side of the absorbent article which faces the user during use. Byhaving an absorbent article with the structure shown in FIG. 6C, it isalso beneficial for the absorbent structure to have an additional layer23. This additional layer will serve to provide liquid impermeability tothe absorbent structure, such that any fluids entering the absorbentcore will not flow through the core to clothing of a user.

This additional layer 23 may be prepared from a variety of materials andis generally, this additional layer constructed of any material whichwill function to be operatively liquid impermeable. The additionallayer, may be a polymeric film, a woven fabric, a nonwoven fabric or thelike, as well as combinations or composites thereof. For example, theshell 14 may include a polymer film laminated to a woven or nonwovenfabric. In a particular feature, the polymer film can be composed ofpolyethylene, polypropylene, polyester, silicone or the like, as well ascombinations thereof. Additionally, the polymer film may bemicro-embossed, have a printed design, have a printed message to theconsumer, and/or may be at least partially colored. Suitably, theadditional layer can operatively permit a sufficient passage of air andmoisture vapor out of the absorbent article 10, particularly out of anabsorbent structure 21 while blocking the passage of bodily fluids andodors often associated with bodily fluids. An example of a suitablematerials for the additional layer 23 can include a breathable,microporous film, such as those described in, for example, U.S. Pat. No.6,045,900 to Haffner et al., the entire disclosure of which isincorporated herein by reference and made a part hereof.

As is stated above, the first area 11 of the shell 14 serves eitherdirectly or indirectly attaches to the body of a user. Stated anotherway, the shell is the body attachment member and the first area 11 isthe portion of the shell 14 which is attached to the body of the user.Depending on the material selected for the shell, the shell may activelyattach to the body of the user using electrostatic means; suction meansor a body adhesive may be placed on the first area 11 of the shell 14 toattach the absorbent article to the body of a user. Electrostatic meanswhich can be used is by selecting the shell material to be a materialwhich has an affinity for the body of a user, such that the shellmaterial “clings” to the body of the user. Examples of such materialsinclude ethylene vinyl acetate, low density polyethylene and othersimilar materials know to those skilled in the art. Suction means may beachieved by shaping the shell to conform to the body of the user, muchlike a contact lens fits to the eye. Generally, suction means can beachieved by forming the shell 14 into a three-dimensional shape. Theeasiest way to achieve body attachment is to place a body adhesive inthe first area 11 of the shell 14.

The body adhesive 44 is positioned on the first area 11 of the firstside 15 of the shell 14. The body adhesive 44 contacts the skin andhair, if present, in the vulva region and possibly the public regionand/or the perinea region of the wearer's body, thereby supporting andholding the absorbent article 10 against the body of the wearer duringuse. The body adhesive 44 can overlie a portion of the first area 11 orcan overlie the entire first area 11 of the shell 14. Generally, thebody adhesive 44 will be present on a least the outer portion or nearthe circumference 11C of the first area near the edge 20 of theabsorbent article. As is shown in FIGS. 1A, 1B, 2, 2A, 4, 5B and 6B and6C, the adhesive may cover the entire first area 11 of the absorbentarticle. Alternatively, the body adhesive 44 may be placed on a portionof the first area 11, as is shown in FIGS. 5 and 5A. The body adhesive44 may also be placed in a pattern of the first area 11. The bodyadhesive 44 can be applied to the first area 11 of the shell 14 of usingany known process including, inkjet printing, screen printing orextruding the body adhesive 44 from one or more nozzles, slot coatingand the like.

Generally, any pressure sensitive adhesive known to those skilled in theart may be used, provided that the pressure sensitive adhesive is not aknown irritant to human skin or that the adhesive is so aggressive thatit causes pain to the user when the absorbent article is removed fromthe skin. It is also desirable that the adhesive is selected such thatthe adhesive does not leave a substantial amount of an adhesive residueon the surface of the skin of the user, when the absorbent article 10 isremoved by the user after use. Particularly suitable pressure sensitiveadhesive materials are disclosed in the commonly assigned U.S. Pat. No.6,213,993 to Zacharias et al., U.S. Pat. No. 6,620,143 to Zacharias etal., the entire disclosure of each is incorporated herein by referenceand made a part hereof. Other suitable adhesives are disclosed in U.S.Pat. No. 5,618,281 to Batrabet et al., the entire disclosure of which isincorporated herein by reference and made a part hereof. Other knownbody adhesives, such as those described in U.S. Pat. No. 6,316,524 toCorzani et al. which is hereby incorporated in its entirety, may also beused. Other examples of pressure sensitive adhesives include, Hydrogels,Hydrocolloids, Acrylics based adhesives, rubber based adhesives, such asKraton based adhesives.

The body adhesive 44 may be positioned on the first area 11 of the shell14 in an open pattern or a closed pattern. By “open pattern” is meantthat the adhesive can have an intermittent or discontinuous patternwhich does not substantially encircle the entire first area 11. Forexample, there are breaks in the body adhesive at certain portions ofthe first area 11. An open pattern of adhesive is shown in FIG. 5.“Closed pattern” means the adhesive 44 would encircle the entire secondarea 12 of the shell. Preferably, the pattern of the body adhesive 44will substantially surround the absorbent structure located in or on thesecond area 12 of the shell 14. As shown in FIGS. 1A, 1B, 2, 2A, 4, 5Band 6B and 6C, the body adhesive 44 is applied in a closed pattern,since the entire body adhesive is applied in a continuous fashion aroundthe first area. An “open” pattern of the adhesive is shown in FIG. 7,which shows the adhesive applied in a discontinuous fashion.Additionally, the adhesive may be applied in portions of the first area11, as is shown in FIGS. 5 and 5A. In the present invention, the closedpattern can be advantageous since the body adhesive 44 may form a sealwith the body of the user which will assist in preventing leaks from theabsorbent article 10. The body adhesive may form a dam, which mayprevent leaks from the entire perimeter of the absorbent article.

In one embodiment of the present invention, as is shown in FIGS. 1A, 1B,2, 2A, 4, 5B and 6B and 6C, the body adhesive 44 may be placed on theentire first area 11, just outside of the absorbent structure 21. Inanother alternative embodiment of the present invention, as is shown inFIG. 5, the body adhesive 44 may placed along the outer portions of thefirst area 11 near the periphery of the shell 14. The body adhesive 44may also be placed on the absorbent structure 21. Generally, however,the body adhesive 44 is confined to being placed on the first area 11 ofthe shell 14, since placing the body adhesive on an area of theabsorbent product 10 which contacts the female genitalia such as thelabia majora may cause discomfort to the wearer of the absorbentproduct.

The adhesive may be applied in a pattern of small discrete dots so as toleave numerous areas free from adhesive. Alternatively, the adhesive maybe applied as a continuous bead, or may be applied as a series ofsemi-continuous beads. Other suitable adhesive patterns may be selectedfor applying the body adhesive 44 to the body-contacting first area 11of the absorbent article 10. For example, adhesive patterns can be oval,swirls, various linear or non-linear arrays of adhesive longitudinally,and/or transversely oriented and reticulated webs having unobstructedinterstices between the adhesive fibers or combinations thereof. Asstated above, the adhesive patterns may be open or closed. The weightsof adhesives are limited to less than about 800 g/m², and generally lessthan about 400 g/m². Generally, the weight of the adhesive is at least20 g/m². Typically, the adhesive is applied in an amount of about 100 toabout 400 g/m². The limitations on the basis weight of the adhesive areimportant to provide the correct adhesive characteristics for applyingdirectly to the wearer's vulva region and optionally the pubic andperinea regions of the wearer's body. If the basis weight is too high,the absorbent article will have a sticky feeling or otherwiseuncomfortable feeling. If the basis weight of the adhesive is too low,there may be insufficient adhesion to the body of the user.

Generally, the body adhesive 44 is applied in a manner which issymmetrical about the longitudinal axis 1 which bisects the absorbentarticle 10 and divides the absorbent article 10 into substantially equalportions. This symmetrical pattern provides the wearer a balanced feelwhen wearing the absorbent article 10. The symmetrical pattern alsoreduces the perception of any associated discomfort when the absorbentarticle 10 is removed from the body.

As is shown in FIGS. 8A and 8B, to protect the body adhesive 44, a peelsheet or release sheet 46 may be used to prevent the body adhesive 44from becoming contaminated, thus loosing its ability to stick to thebody of an user and/or prematurely adhering to an unintended surface.Suitable materials for use as a peel strip 46 are well known in the artand are commercially available. Examples of suitable peel sheets orrelease sheets include, a silicone coated Kraft paper, a silicone coatedfilm or the like. Other release coating includes coating containingpolytetrafluoroethylene. The peel sheet or release sheet 46 may extendbeyond one or both of the ends and/or sides of the shell, as shown inFIG. 8B. Alternatively, the release sheet 46 may be sized to only coverthe body adhesive on the first area 11 of the shell 14, as is shown inFIG. 8A. In yet another embodiment of the present invention, releasesheet may extend beyond the adhesive at one or more locations, such asone of the ends or one of the sides of the shell as is shown in FIG. 8Cby providing the release sheet 46 with a tab 47 for the user to grasp toremove the release sheet 46 from the absorbent article 10 and the bodyadhesive 44 on the absorbent article. When the release sheet 46 extendsbeyond the adhesive, it is generally easier for the user to remove therelease sheet 46 to place the absorbent article 10 for use.

Alternatively, the release sheet 46 may be provided with a pressuresensitive adhesive to hold the release sheet 46 in place when theabsorbent article is devoid of an adhesive for body attachment. In thisconfiguration, the release sheet serves to protect the absorbentstructure and first side of the shell from dirt and damage prior to use.

In another alternative, a release sheet may not be necessary. Forexample, the absorbent article may be rolled, folded onto itself orstacked upon each other. In these configurations, a release sheet is notneeded. If rolled, the body adhesive 44 will generally contact thesecond side 17 of the shell 14. The body adhesive 44 should releasablystick to one second side of the shell by readily releasing when unrolledby the user or wearer. In addition, the body adhesive 44 should notleave a residue on the second side 17 of the shell. This shouldsimilarly occur when the absorbent articles 10 are stacked upon eachother such that the body adhesive 44 of one article will attach thesecond side of the shell of a second article. In another possibleconfiguration, the absorbent article may 10 be folded along thelongitudinal axis 1 of the lateral axis such that the body adhesive 44in one area comes into contact with body adhesive in another area. Inthe folded configuration, the body adhesive should be selected such thatthe body adhesive will release from itself when manipulated by a user.

The dimensions and shape of the shell 14 should be such that it isappropriately sized for its intended use. The same is true for the sizeand shape of the absorbent structure. Generally, the size and shape ofthe absorbent structure 21 will dictate the size of the shell 14. Theshape of the shell 14 is selected so that the absorbent article willhave a comfortable feeling for the user, which providing protectionagainst leaks and preventing the absorbent article from becomingdislodged from the body of the user during user. Generally, the shellwill be curved to fit the body of a user. The shell 14 also generallygives the absorbent article 10 its overall size and shape in thelongitudinal 1 and lateral 2 directions.

When the absorbent article is intended for use as a pantiliner, asanitary napkin or a feminine incontinence article, the shell 14 shouldbe wider and longer than the absorbent structure 21 attached to thesecond area 12 of the shell 14. The absorbent structure should be atleast as wide and as long as the labia majora of the user. As a result,to fit most women, the absorbent structure is longer in the longitudinaldirection than it is wide in the lateral direction of the absorbentstructure. Generally, for most women, the labia majora are generallybetween about 40 mm and about 70 mm in width and between about 80 mm and150 mm in length. Ideally, the absorbent structure should be wider thanthe labia majora and slightly longer that the labia minora and slightlylonger than or equal to the labia majora. Generally, the absorbentshould be between about 40 mm and 90 mm in width in the lateraldirection and between about 95 mm and about 150 mm in length thelongitudinal direction. The shape of the absorbent structure 21 willgenerally tend to be oblong and may be an oval, a rectangle, tear dropshaped, hourglass shaped or racetrack shaped. As can be seen in FIGS.1A, 5, 5B, 6, B, 7 and 9, the absorbent structure 21 has a generallyelliptical or oval shape to match the size and shape of the vaginal areaof most women. An example of a teardrop shaped absorbent is shown inFIG. 1A.

Generally, the shape of the shell 14 may vary from a generally ovalshape, as shown in FIGS. 1A and 1B to a shape which is a generallyhourglass-like shape, shown in FIG. 5A. By generally hour glass shape,it is meant shape in which the sides 19 of the shell 14 converge towardsone another at a point away along the longitudinal axis 1 of the shell14 to form a narrowest portion 33 of the absorbent article. Generally,the hourglass-like shape provides a cut-out for the user's legs. Byhaving an hourglass-like shape, the shell 14 will not be attached to thelegs of a user during use. This will provide more comfort for the userof the absorbent article 10. The shape of the shell 14 should beselected such that the absorbent article 10 will be comfortable to wear,while providing very effective leakage protection to the user. The shell14 and the absorbent structure 21 should be able to adapt to thecurvature of a users body during use. Other possible shapes for theshell 14 are also shown in FIGS. 5, 5A, 5B, and 6A. Other shapes notspecifically shown may also be used, provided that the shape willprovide comfort to the user of the absorbent article.

To obtain an effective attachment of the absorbent article to the user,when the absorbent article is used as a sanitary napkin or anincontinence article, generally the width of the of the shell should beat least 10 mm on either side of the labia majora. Generally, the shell14 of the absorbent article 10 will have a width, in the lateraldirection 2, between about 50 mm up to 200 mm or more. Typically, theshell will be between about 60 and 120 mm at its narrowest point. Thiswill allow the shell 14 to have a first area 11 that can be effectivelyattached to the skin of a user on either side of the labia majora.

In addition, the absorbent article 10 may also be configured to have ananterior portion 64, a central portion 65 and a posterior portion 66, asis shown in FIG. 9. As used herein, the term “anterior” refers to thedirection towards the front of the wearer during use. As used herein,the term “posterior” refers to the direction towards the back of thewearer during use. A particular embodiment is shown in FIG. 8 of anabsorbent article having a configuration designed to fit specific areasof the vulva region of a user. By providing specific portions forattachment to specific areas of the body of the user, the absorbentarticle may be configured to better fit the body of the user. Theanterior portion 64 of the absorbent article will be the portion of theabsorbent article between the absorbent structure 21 and the first end61 of the absorbent article 10. The posterior portion 66 of theabsorbent article 10 will be the portion of the absorbent articlebetween the absorbent structure 21 and the second end 62 of theabsorbent article 10. Generally, the posterior portion 66 will bedesigned to be placed between the vagina area and the anal area of theuser. The anterior portion 64 is designed to be placed on the monsVeneris region of a female user. The central portion 65 of the absorbentarticle 10 is designed to cover the vagina area of the user and the skinarea surround the lateral sides of the labia majora, when the absorbentarticle is used as a pantiliner, sanitary napkin or an incontinencearticle. In an alternative use, the absorbent article of the presentinvention may also be used as an underwear replacement, or a guard for aswimming suit.

To obtain an effective attachment to the body of the user, the shell 14can be configured to be anatomically correct for a user. As is shown inFIGS. 9 and 10, the shape of the absorbent article 10 is such that itwill correctly and securely fit in the vulva region of a user. Thegeneral shape of the absorbent article shown in FIG. 10 has been foundto effectively attach to the vulva region of female users of theabsorbent article. Additional features may be included to ensure ananatomically correct shape. For example, in the posterior region of theabsorbent article 10, more particularly, the posterior region of theshell on the first side 15, the shell 14 may be imparted with athree-dimensional protrusion 67, as shown in FIGS. 9 and 10. Theprotrusion 67 acts to fit comfortably in the perinea region of the user.The protrusion 67 may be formed from the shell material of may be formedfrom the body adhesive 44. By providing the three-dimensional protrusion67, the absorbent article can effective fit to the typical body shape ofthe female user, thereby preventing leaks form the posterior portion ofthe absorbent article. The protrusion 67 may also serve as a guide tothe user in placement of the absorbent article 10 on the body prior touse.

The absorbent article of the present invention may have other featureswhich aid the user to place and remove the absorbent article from thebody. As is shown in FIGS. 10A and 10B, the second side 12 of the shell14 may be provided with positioning aids such as a finger pocket 99,shown in FIGS. 11A and 11B, or finger grooves in the shell material, asis shown in FIG. 11B. The finger pocket 99 has an opening 98 towards theanterior portion 64 or first end 61 of the absorbent article 10. Thepocket 99 gives the user a location to place her fingers duringplacement of the absorbent article 10 onto the user's body. The pocket99 may be an opening wide enough for the user to place at least twofingers in the pocket. Alternatively, may be two or more openings whichallows the user to place only one finger in each opening. Other similarpositioning aids may be used to help guide a user to properly place theabsorbent article for use. For example, grooves may be placed in thesecond side 12 of the shell 14 opposite the absorbent structure. Thismay allow the user to feel the location of the absorbent structurerelative to the vulva region during application of the absorbent article10 to the vulva region of the body. The pocket 99 may also assist theuser in removing the absorbent article from their body.

The absorbent article 10 may also be provided with a removal aid whichprovides the user with an easy way to grasp and remove the absorbentarticle applied to the body. One particular removal aid is shown in FIG.10B including a tab 92 located on the first end 61 of the shell which isnot adhered to the body or is devoid of adhesive. Alternatively, otherremoval aids, such as having an area of the first end 61 being devoid ofthe body attaching adhesive 44. Other types of removal aid which may bepresent include loops, and pull strings. The removal aid allows the userto effectively begin the process of gentling removing the absorbentarticle from the body of the user, without the need of having to find aportion of the shell which may not be completely attached.

Other features or additives may be incorporated into the absorbentarticle of the present invention. For example, the absorbent article maycontain an odor control agent, or a fragrance, skin wellness agents andother similar additives currently used in currently available absorbentarticles. Any odor control agent or, fragrance known to those skilled inthe art may be used in the absorbent article of the present invention.The odor control agent or fragrance may be added in various componentsof the absorbent article, including the shell 14, the absorbentstructure 21 of the body adhesive 44. Skin wellness additives may beadded onto the absorbent structure, any portion of the first area 15 ofthe shell not attached to the user or in the body adhesive 44.

Generally, to apply the absorbent article 10 to the body of a user, therelease sheet 46, protecting the absorbent structure and adhesive, ifpresent, is removed from first surface of the shell. Next, the userpositions the absorbent structure of the portion of the body in whichabsorbency is needed. If positioning pockets or other positioning aidsare present on the absorbent structure, the user may optionally usethese positioning aids to properly place the absorbent article for use.In the case of sanitary napkins and incontinence absorbent articles forfemales, the absorbent is positioned over the vagina area such that theabsorbent structure will absorb body fluids. The user then checks toensure that the first area 11 of the shell or the adhesive 44, ifpresent, is contacting the skin around the vagina area.

If the absorbent article is intended to have a front and a back portion,the user first identifies the anterior portion 64 and/or the posteriorportion 66 of the absorbent article. To aid in identification of theanterior and posterior portions, indicia located on the release sheet,shell or absorbent to indicate the anterior portion and/or posteriorportion of the absorbent article may be present. Indicia can be simplylettering or a picture to indicate the front or back of the absorbentarticle. Once anterior portion and posterior portion are identified bythe user, the user places the absorbent article in the same mannerdescribed above.

In each case, the absorbent structure, which is designed to cover thelabia majora of the user, may be positioned with the aid of theabsorbent structure. More specifically, the absorbent structure, whensized and shaped to the approximate size of the labia majora, can serveto guide the placement of the absorbent structure over the labia majora.Once properly placed, pressure is applied by the user to the secondsurface of the shell which will allow the first surface of the shell tocontact the skin of the user, or to allow any adhesive applied to thefirst surface to be applied to the skin of the user.

By having the absorbent article 10 attached to the body of a user, theabsorbent article 10 will tend to move with the skin of the user. Thisresults in a comfortable to wear absorbent article which will be lesslikely to leak than conventional absorbent articles. The absorbentarticle has a very close to the body fit which may provide improveddiscretion for the user.

Other benefits of the absorbent article 10 of the present invention mayalso be provided. For example, when the first side of the shell has anadhesive applied thereto, upon removal of the absorbent article afteruser, the user may fold the first side of the shell onto itself todispose of the used absorbent article. An effective seal may be formedaround the perimeter of the shell, thereby effectively encapsulating theabsorbent structure within a closure. As a result, any odors associatedwith the absorbed fluids will be contained within the shell material.

Although the present invention has been described with reference tovarious embodiments, those skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention. As such, it is intended that the foregoingdetailed description be regarded as illustrative rather than limitingand that it is the appended claims, including all equivalents thereof,which are intended to define the scope of the invention.

1. An absorbent article comprising: a shell having a first side and a second side, the first side having a first area and a second area, wherein the first area surrounds a majority of the second area, the shell having a three-dimensional concave shape such that the first side of the shell is an inward curving surface; and an absorbent material located entirely within the second area of the shell.
 2. The absorbent article according to claim 1, wherein the second area of the shell has a second area circumference, the first area of the shell surrounds at least 75% of the second area circumference.
 3. The absorbent article according to claim 2, wherein the first area of the shell surrounds at least 95% of the second area circumference.
 4. The absorbent article according to claim 1, wherein the shell is prepared from a material comprising a woven web, nonwoven web, a gel, a film, a sheet of a polymeric material or a laminate of one or more of these materials.
 5. The absorbent article according to claim 4, wherein the shell comprises a laminate of a woven or nonwoven web with a gel, a film of a sheet of a polymeric material.
 6. The absorbent article according to claim 5, wherein the shell comprises a laminate of a woven or a nonwoven web with a sheet of a silicone polymer.
 7. The absorbent article according to claim 1, wherein the shell comprises a silicone material.
 8. The absorbent article according to claim 1, wherein the first area of the shell comprises adhesive properties, wherein the adhesive properties provide a means to attach the absorbent article to the wearer's skin surrounding vulva region of the wearer's body.
 9. The absorbent article according to claim 8, wherein the first area of the shell comprises an adhesive applied thereto.
 10. The absorbent article according to claim 9, wherein the first area is essentially entirely covered by the adhesive.
 11. The absorbent article according to claim 8, wherein the adhesive properties are imparted to the first area of the shell by the physical properties of materials used to prepare the shell.
 12. The absorbent article according to claim 1, further comprising an anterior portion and a posterior portion, wherein the posterior portion is adapted to attach to the body of a user between the vulva region and the anal region of the body of the user and the anterior portion is adapted to attach to the mons Veneris region of a user.
 13. The absorbent article according to claim 12, wherein the shell has an anatomically correct shape for placement in the vulva region of a user.
 14. The absorbent article according to claim 13, wherein the posterior portion further comprises a protrusion extending upward from the first side of the shell.
 15. The absorbent article according to claim 12, wherein the absorbent structure is sized and shaped to cover the labia majora of a user.
 16. The absorbent article according to claim 12, wherein the absorbent structure comprises an absorbent core and a body side liner, wherein the absorbent core is positioned between the body side liner and the shell. 